NHTSA ID Number: 10216489
Manufacturer Communication Number: 21M05-S1
TSB/Document Date: 2022-07-28
Summary
Certain 2017-2022 Model Year Super Duty Vehicles Equipped with a Power Release Tailgate - Unintended Tailgate Opening. In the affected vehicles, some customers report experiencing an unintended tailgate opening and may have previously serviced their vehicle for this concern. Ford had developed an enhanced remedy for customers who may want this enhanced repair performed n their vehicle.
BK-VT wire from the relay into Pin 21 for a black connector or pin 2 for a grey connector. Reinstall the
white locking tab, attach C248 to the BCM retainer and reconnect C248. See Figure 47.
MALE END OF
C248
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
RETAINER
WHITE LOCKING TAB
FIGURE 47
BK-VT WIRE
STUD FOR
FROM RELAY
MISSING NUT
20036UU
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD
MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
ATTACHMENT III
PAGE 30 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
65. On the floor of the front passenger side door, cut the wire harness tie strap. Using a Harness Ripper
tool or equivalent, carefully open up the harness 75 mm (3 inch) from the front of the wire harness
shield to expose the wiring. See Figure 48.
FRONT OF
VEHICLE
EXPOSE
WIRING
TIE STRAP
WIRE HARNESS
SHIELD
45 MM
(2 INCH)
20036QQ
FIGURE 48
66. Position back and connect the negative battery cable(s). Please follow the WSM procedures in
Section 414-01.
67. Locate the wire bundle within the wiring harness. Using a Vernier Caliper tool, measure all 3 Grey-
Brown (GY-BN) wires and isolate the 1.5 mm (0.06 inch) wire within the bundle. This is the largest
wire within the bundle. See Figure 49. Cut the 1.5 mm (0.06 inch) wire. Test the vehicles door
locks. If the door locks work, the correct wire has been cut. If the door locks do not work, repair the
wire and repeat Step 67.
1.5 MM (0.06 INCH)
DIAMETER WIRE
WIRE BUNDLE LOCATED
IN THE WIRING HARNESS
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
20036RR
PLACE
COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
FIGURE 49
PLACE COPY HERE
ATTACHMENT III
PAGE 31 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
68. Disconnect the negative battery cable(s) and position aside. Please follow the WSM procedures in
Section 414-01.
69. Apply heat shrink tubing and seal the front of vehicle end of the cut wire. Strip, solder and seal with
heat shrink the jumper wire from C248 to the rear of the vehicle end of the cut wire. See Figure 50.
Re-wrap the harness using the appropriate (black or orange) electrical tape.
FRONT OF
VEHICLE
JUMPER WIRE FROM
MALE END C248
SEALED WIRE
(FRONT OF
VEHICLE END)
ELECTRICAL
TAPE
20036VV
FIGURE 50
70. Reinstall the Glove Compartment. Please follow the WSM procedures in Section 501-12.
71. If equipped, remove the bedliner tailgate cover. See Figure 51.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
20036WW
E196058 CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
FIGURE 51
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 32 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
72. Remove the tailgate access panel bolts and the tailgate access panel. See Figure 52.
20036XX
FIGURE 52
73. Remove the tailgate latch control assembly nuts and position the tailgate latch control assembly
towards the rear of the vehicle. See Figure 53.
FRONT OF
VEHICLE
TAILGATE LATCH
CONTROL ASSEMBLY
TAILGATE LATCH
CONTROL
ASSEMBLY NUT
x2
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
20036YY
FIGURE 53
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 33 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
74. Disconnect the electrical connector and the push pin retainer. See Figure 54.
NOTE: Tailgate latch control assembly shown outside of the vehicle for clarity.
20036ZZ
FIGURE 54
75. Remove the white locking tab and the Blue-Grey (BL-GY) wire from the tailgate latch control
assembly connector. Cut off the terminal of the BL-GY wire. See Figure 55.
WHITE LOCKING
TAB
TERMINAL REMOVED
FROM BL-GY WIRE
STUD FOR
MISSING NUT
STUD FOR
MISSING
NUT
20036AAA
TAILGATE LATCH CONTROL ASSEMBLY
ELECTRICAL CONNECTOR
FIGURE 55
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
STUD FOR
MISSING NUT
STUD FOR
ATTACHMENT III
PAGE 34 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
76. Seal the BL-GY wire using heat shrink tubing. Install the non-sealed end of the BK-VT Tailgate Jumper
Harness wire into the tailgate latch control assembly electrical connector. See Figure 56.
TAILGATE LATCH
CONTROL ASSEMBLY
ELECTRICAL CONNECTOR
SEAL BL-GY WIRE WITH
HEAT SHRINK TUBING
NON-SEALED
END OF BK-VT
TAILGATE
JUMPER
HARNESS WIRE
20036BBB
FIGURE 56
77. Bend back the sealed wire and secure using Coroplast® 837 or Equivalent Electrical Wire Harness
Tape. Install the white locking tab. See Figure 57.
BEND WIRE BACK
AND APPLY TAPE
WHITE LOCKING
TAB
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
20036CCC
FIGURE 57
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
STUD FOR
MISSING NUT
STUD FOR
ATTACHMENT III
PAGE 35 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
78. Apply a piece of Coroplast® 837 or Equivalent Electrical Wire Harness Tape after the push pin retainer
to secure the Tailgate Jumper Harness. See Figure 58.
COROPLAST® 837 OR
EQUIVALENT TAPE
TAILGATE JUMPER
HARNESS
20036DDD
FIGURE 58
79. Reconnect the electrical connector and the push pin retainer. See Figure 59.
NOTE: Tailgate latch control assembly shown outside of the vehicle for clarity.
FRONT OF
VEHICLE
STUD FOR
MISSING NUT
STUD FOR
20036EEE
MISSING
NUT
FIGURE 59
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
STUD FOR
MISSING NUT
STUD FOR
ATTACHMENT III
PAGE 36 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
80. Using a straightened coat hanger, tape the sealed terminal end of the Tailgate Jumper Harness Wire
to one end of the coat hanger. Route the wire and coat hanger on the LH side of the tailgate latch
control assembly and through the opening in the center bottom of the tailgate. Continue to pass
through the opening in the bed and down through the bottom of the vehicle. See Figure 60.
BED OPENING
TAILGATE OPENING
TAILGATE OPENING
FRONT OF
VEHICLE
TAILGATE LATCH CONTROL ASSEMBLY
20036FFF
FIGURE 60
81. Secure the Tailgate Jumper Harness using tie straps and trim any tie strap excess length.
See Figure 61.
TIE STRAP
TIE STRAP
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
FRONT OF
VEHICLE
20036GG
FIGURE 61
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
ATTACHMENT III
PAGE 37 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
82. Position back the tailgate latch control assembly and install the nuts. See Figure 62.
• Torque 80 lb.in (9 Nm)
FRONT OF
VEHICLE
TAILGATE LATCH
CONTROL ASSEMBLY
TAILGATE LATCH
CONTROL
ASSEMBLY NUT
x2
21685BB
FIGURE 62
83. Remove the Tailgate Release Handle. Please follow the WSM procedures in Section 501-14.
84. Remove and discard the Tailgate Release Switch. See Figure 63.
1
2
STUD FOR
MISSING NUT
STUD
FOR
20036XXX
MISSING NUT
FIGURE 63
STUD FOR
85. Install the new Tailgate Release Switch by reversing the removal procedure. See Figure 63.MISSING NUT
86. Install the Tailgate Release Handle. Please follow the WSM procedures in Section 501-14.PLACE COPY HERE
• Camera alignment is not required.
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
STUD FOR
ATTACHMENT III
PAGE 38 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
NOTE: For 2017-2019 model year vehicles, the Safety Recall 19S48 Tailgate Jumper Harness Kit MUST
be installed in order to complete this repair. See Figure 64.
NOTE: For 2020-2022 model year vehicles, all vehicles are equipped with the Tailgate Jumper Harness
Kit from the manufacturer. See Figure 64.
FRONT OF
VEHICLE
1918CC
FIGURE 64
87. Position the vehicle on a hoist. Please follow the WSM procedures in Section 100-02.
88. Using the vehicle spare tire rod, lower the spare tire and secure it out of the way using a ratchet strap
or other similar device.
89. Disconnect the black inline C4003 and the grey and black 2 pin connectors. See Figure 65.
INLINE
C4003
STUD FOR
GREY 2 PIN MISSING NUT
CONNECTOR
STUD FOR
MISSING NUT
BLACK 2 PIN
CONNECTOR STUD FOR
MISSING NUT
FRONT OF
VEHICLE
20036HHH
PLACE
COPY HERE
FIGURE 65
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
ATTACHMENT III
PAGE 39 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
90. Remove the tape and convolute of the female side of the Grey 2 pin connector to expose the end of
the Green-Brown (GN-BN) dummy wire. See Figure 66.
END OF GN-BN
DUMMY WIRE
TAPE AND
CONVOLUTE
FEMALE END OF
GREY 2 PIN CONNECTOR
FRONT OF
VEHICLE
20036KKK
FIGURE 66
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 40 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
91. On the female end of the Grey 2 pin connector, cut the GN-BN dummy wire halfway between the heat
shrink and the connector. Cut off the sealed terminal on the Tailgate Jumper Harness. See Figure 67.
TAILGATE JUMPER
HARNESS
FEMALE END OF
GREY 2 PIN
CONNECTOR
END OF GN-BN
DUMMY WIRE
SEALED TERMINAL OF THE
TAILGATE JUMPER HARNESS
20036LLL
FIGURE 67
92. Solder and heat shrink the Tailgate Jumper Harness to the GN-BN dummy wire of the grey 2 pin
female end connector. See Figure 68.
FEMALE END OF
GREY CONNECTOR
GN-BN DUMMY
WIRE
TAILGATE JUMPER
HARNESS
STUD FOR
MISSING NUT
STUD FOR
SOLDER ANDMISSING NUT
HEAT SHRINK 20036MMM
FIGURE 68
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2022 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2022
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 41 OF 51
CUSTOMER SATISFACTION PROGRAM 21M05-S1
93. Remove 76 mm (3 in) of tape and convolute of the male end of C4003 to expose the wiring. Locate the
Grey-Brown (GY-BN) wire in C4003 (pin 10). See Figure 69.
76 MM (3 INCH)
FRONT OF
VEHICLE
GY-BN WIRE
(PIN 10)
TAILGATE END
OF C4003
20036III
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TSB/Document ID: 21M05-S1
Replacement Service Bulletin Number:
MFR Communication Date: 2022-07-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
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